Supercapacitor Stack Dielectric Frames for Leakage Prevention
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Solution Overview
Problem
Supercapacitors face issues with electrolyte leakage and mechanical instability at high temperatures and voltages, leading to potential swelling or bursting, which reduces their lifespan and reliability.
Innovation Solution
The use of matching dielectric frames with an outer perimeter larger than the current collectors, extending beyond the edges to provide enhanced sealing and mechanical protection, along with self-aligning features for precise assembly and automation in the manufacturing process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If dielectric frames with outer perimeter larger than current collectors are used, then sealing and mechanical protection are enhanced, but device complexity increases
Solution Approach 1:
The device is divided into modular units, each comprising a current collector assembly with integrated dielectric frames. These modular units can be independently manufactured and then stacked to form the complete supercapacitor device, reducing overall complexity while maintaining enhanced sealing performance.
Solution Approach 2:
The dielectric frames are merged with the current collector assemblies to form integrated units. The frames extend beyond the current collectors and are designed to mate with adjacent units, providing both electrical isolation and mechanical sealing in a single integrated structure rather than as separate components.
2Reliability
If matching dielectric frames extending beyond current collectors are used, then electrolyte leakage is reduced, but manufacturing complexity increases
Solution Approach 1:
The dielectric frames incorporate self-aligning features such as protrusions that fit into corresponding recesses in adjacent frames. This self-aligning mechanism automatically positions the frames correctly during assembly, eliminating the need for complex external alignment tools or procedures and reducing manufacturing complexity.
Solution Approach 2:
The dielectric frames are pre-formed with integrated sealing structures and self-aligning features before assembly. This preliminary preparation ensures that when the modular units are stacked, the frames automatically mate correctly and create sealed environments, simplifying the overall manufacturing process.
3Stability of the object's composition
If dielectric frames are attached between conductive sheets and insulating sheets, then mechanical stability at high temperatures is improved, but device complexity increases
Solution Approach 1:
The dielectric frames are merged with the current collector assemblies to form integrated units. The frames extend beyond the current collectors and are designed to mate with adjacent units, providing both electrical isolation and mechanical sealing in a single integrated structure rather than as separate components.
Solution Approach 2:
The device employs composite construction with dielectric frames made from temperature-stable materials that maintain their mechanical properties at high operating temperatures. These frames are combined with conductive sheets and insulating sheets to create a multi-material structure that provides both thermal stability and electrical functionality.
Data Source
AI summary
The present invention provides a process for fabricating an n-cell supercapacitor stack, including a step of providing at least n+1 identical, or substantially identical, electrically inert conductive sheets having a defined perimeter, n identical, or substantially identical, ion-permeable insulating sheets having a defined perimeter, n identical, or substantially identical, first electrodes having a defined perimeter, n identical, or substantially identical, second electrodes having a defined perimeter, and at least n matching dielectric frames having an outer perimeter, which is larger than the perimeter of the conductive sheet and the perimeter of the insulating sheet; a step of assembling the supercapacitor stack, a step of disposing an additional conductive sheet on top of the nth second electrode; and a step of attaching adjacent units onto one another, such that at least one of the frames within each unit is attached to at least one of the frames within each respective unit adjacent thereto. Further provided is a sealing system for use in fabricating a supercapacitor stack, which includes matching current collectors and separators having externally extending framing structures.